CN110925338A - 制动盘和用于生产制动盘的方法 - Google Patents

制动盘和用于生产制动盘的方法 Download PDF

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CN110925338A
CN110925338A CN201910821910.9A CN201910821910A CN110925338A CN 110925338 A CN110925338 A CN 110925338A CN 201910821910 A CN201910821910 A CN 201910821910A CN 110925338 A CN110925338 A CN 110925338A
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layer
corrosion
brake disc
wear
resistant layer
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马克·奥利弗·雷蒂希
雅罗斯瓦夫·格罗乔维斯
托马斯·帕维尔·格拉比克
克莱门斯·玛丽亚·沃伯特
安德烈亚斯·旺克
亚历山大·黑茨克
克里斯臣·施门戈莱尔
卡琳·穆勒-罗登
克劳斯·克斯根
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Ford Global Technologies LLC
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Abstract

本发明涉及一种用于陆地车辆的车轮制动器的制动盘(1)，该制动盘(1)具有主体(2)，该主体(2)由灰铸铁制成，该主体(2)具有至少一个轴向摩擦侧(3)、应用到轴向摩擦侧(3)的至少一个抗腐蚀层(4)，和应用到抗腐蚀层(4)的至少一个抗磨损层(5)。为了为制动盘(1)提供成本效益的涂层，该涂层实现具有由灰铸铁构成的主体(2)的制动盘(1)的摩擦面的增强的耐腐蚀性和耐磨性，该抗腐蚀层(4)是渗锌层。

Description

制动盘和用于生产制动盘的方法
技术领域
本发明涉及一种用于陆地车辆的车轮制动器的制动盘，该制动盘具有由灰铸铁制成的主体，该主体具有至少一个轴向摩擦侧、应用到轴向摩擦侧的至少一个抗腐蚀层和应用到抗腐蚀层的至少一个抗磨损层。本发明进一步涉及一种用于生产陆地车辆的车轮制动器的制动盘的方法，其中主体由灰铸铁制成，该主体具有至少一个轴向摩擦侧，至少一个抗腐蚀层被应用到轴向摩擦侧，并且至少一个抗磨损层被应用到抗腐蚀层。
背景技术
用于陆地车辆的车轮制动器的传统制动盘可以使用砂铸法由低成本的灰铸铁材料制造。该灰铸铁材料可以通过铸造和随后的车削或磨削在摩擦环表面的区域中转变成具有所需表面光洁度的所需形状。
由于铸造结构中的石墨薄片具有良好的导热性，灰铸铁材料确实非常适用于制动盘的生产，但灰铸铁材料的低硬度(约200HV至约230HV)意味着它仅具有有限的耐磨性，特别是与欧洲市场上使用的制动衬片配合。制动衬片的摩擦材料包含磨料物质，该磨料物质确保在很宽的温度范围内稳定的摩擦系数。缺点是增加的制动盘磨损。
在欧洲以外的市场中，马达制造商使用NAO摩擦材料(非石棉有机摩擦材料)，该材料会使制动盘上的磨损明显减少，尽管摩擦系数仅在高达约400℃保持稳定。因此，磨损颗粒和细粉尘在制动过程中形成。公众对道路交通引起的市中心空气的细粉尘污染的认识日益提高。此外，许多车辆客户抱怨昂贵的铝制轮辋通过来自盘式制动器的结壳磨损产品严重污染。
此外，灰铸铁材料具有非常差的耐腐蚀性。在仅仅一天的雨天天气之后，如果车辆没有被移动，则制动盘通常是锈红色的。只有当生锈的表面受到应力并通过制动衬片的磨损作用移除时，才能获得金属清洁、视觉上吸引人的表面。然而，在混合动力车辆的情况下，这种具有粗锈红色表面的制动盘仅在相对较重的制动(>0.3·g(g：由于重力引起的加速度)情况下受到足够的机械应力。在这种情况下，可能存在制动颤动和/或制动衬片的损坏和/或令人不愉快的噪音产生。
因此，已经提出了非常多的用于制动盘的涂层解决方案，以便减少所述的缺点。铁素体低温汽车-碳氮共渗(FNC)方法提供临时腐蚀和磨损保护。然而，一旦厚度仅为10μm的薄氮化区由磨损而已经磨损，这种保护效果在仅约10,000km后就消失。特别是在具有高磨损作用的衬片的情况下，如ECE标准所规定的，涂层很快被移除。然而，当使用NAO衬片时，以价格适中的这种临时保护在欧洲以外可能是有意义的。如果，即在雨天天气将新的车辆停放在经销商外几天，短期的防腐蚀将使客户对具有昂贵铝制轮辋的车辆产生更好的视觉印象，即使该效果随后在几周/几个月之后消失。
此外，具有化学镍腐蚀屏障和使用高速火焰喷涂方法(HVOF方法)形成的WC-Cr3C2-Ni顶层的PSCB(＝保时捷表面涂层制动器)制动盘(其应该导致细粉尘排放减少90％)已进入市场。然而，这种非常昂贵的硬质合金涂层不能应用于全世界的所有制动盘，因为战略上重要的WC材料数量不足。
DE 10 2014 006 064 A1公开了一种灰铸铁制动盘，在该灰铸铁制动盘上各种层***用来防止腐蚀和磨损。在这种情况下，首先将具有底切的细槽引入到摩擦环中以便获得随后应用的热喷涂层的良好键合。首先，然后应用软NiCr等离子喷涂，这旨在阻止硬顶层中可能的裂缝。然而，为了确保还提供必要的防腐蚀并且能够避免磨损涂层的表面下腐蚀，灰铸铁盘在引入键槽之后经受一次或两次氮化和氧化边界层处理。随后，通过热喷涂应用粘附和抗磨损层。
此外，抗腐蚀层已经通过等离子体粉末沉积焊接方法或激光沉积焊接方法应用。然而，在这种情况下，已经发现制动盘的灰铸铁材料中的石墨薄片在密集附接区的生产中具有破坏性影响。在DE 10 2010 048 075 B4中，允许不含石墨薄片的灰铸铁制动盘的表面的各种方法被提出，这些方法涉及通过避免腐蚀性介质进入石墨薄片来优化粘附并减少具有热喷涂抗磨损层的灰铸铁制动盘上的表面下腐蚀。
DE 10 2010 052 735 A1涉及一种具有制动盘主体的制动盘，该制动盘主体具有至少一个涂覆有热喷涂层的摩擦环表面。在摩擦环表面上延伸的是至少一个凹陷线，该凹陷线至少在相对于其底部垂直的壁上具有底切，其中底切凹陷线为热喷涂层提供粘附基底。
DE 10 2012 022 775 A1涉及一种防腐蚀复合制动盘，该复合制动盘具有通过齿部连接的制动盘锅和摩擦环。摩擦环的齿部涂覆有富锌涂层材料，并且制动盘锅的齿部涂覆有锌-镍涂层。
JP 2005 239 115 A公开了一种制动转子，该制动转子具有防锈涂层，该防锈涂层通过在紧固凸缘的外表面上热浸镀锌而产生，该紧固凸缘是制动转子的紧固表面。
JP 2009 168 162 A公开了一种盘式制动器转子，该盘式制动器转子具有摩擦表面，该摩擦表面被涂覆有磷酸盐薄膜并且用强碱经受表面处理，从而确保摩擦表面上的锌化合物。
DE 10 2014 004 616 A1涉及一种抗磨损层，该抗磨损层包含在制动盘的制动表面上的铁基合金。该组合物具有按重量计0.5％至2％的C、按重量计3％至13％的Al，和钢中典型的痕量污染物的剩余部分，以使总量达到按重量计100％。
DE 10 2015 122 325 A1涉及一种制动盘，该制动盘具有外表面、第一和第二制动表面和包含在第一制动表面上的多个同心凹槽，第一和第二制动表面彼此相对并且分别由外表面界定，以形成相对的第一和第二制动表面边缘。
可通过http://brakedisc.blogspot.com/上的链接检索到的出版物公开了一种具有用于腐蚀控制的锌涂层的制动盘。
US 8 006 740 B2公开了一种用于生产制动转子的方法，该方法包含制造多个金属***部分。每个***部分包含内侧和外侧，该外侧具有多个紧固元件，这些紧固元件连接到内侧。该方法还包括将多个***部分定位在模具中，以使***部分中的一个的内侧面向另一个***部分的内侧。该方法还包括将熔融铝引入到模具中，以使熔融铝接触每个***部分的内侧。该方法进一步包括在铝和至少一个***部分的至少一部分之间形成机械连接。
可通过https://www.sciencedirect.com/science/article/pii/S0924013609-002325链接检索到的出版物公开了用脉动水射流处理铝表面。
发明内容
本发明的目的是提供一种用于制动盘的低成本涂层，该涂层允许具有由灰铸铁制成的主体的制动盘的摩擦表面的改进的耐腐蚀性和耐磨性。
根据本发明，该目的通过具有权利要求1的特征的制动盘来实现，其中抗腐蚀层是渗锌层。
应当注意的是，在以下描述中单独呈现的特征和措施可以以任何技术上可行的方式组合，从而产生本发明的进一步实施例。该描述特别是结合附图另外表征和具体说明本发明。
根据本发明，活性锌腐蚀屏障通过应用到制动盘的轴向摩擦侧的抗腐蚀层或渗锌层来形成。因此，抗腐蚀层通过渗锌方法或所谓的包扩散方法应用到轴向摩擦侧并因此产生。在渗锌方法的情况下，制动盘可以在锌与硅砂/刚玉的混合物中加热直到最高419℃，并且更特别地直到锌的熔点。在这种情况下，即使在低于锌熔点的温度下，也会形成锌蒸气，该锌蒸气在主体的表面或轴向摩擦侧上形成均匀的铁-锌边缘层，而不会如在热浸镀锌的情况下形成氢气。由于低过程温度，所以没有制动盘的翘曲。
这种坚硬的富锌抗腐蚀层为在不进行任何机械加工或刚玉喷射处理-例如，使用高速火焰喷涂方法(HVOF方法)的情况下将抗磨损层应用到其上提供了理想的条件。如果为此目的首先必须在抗腐蚀层上实施喷砂处理，则存在例如厚度为50μm直到最大100μm的薄的抗腐蚀层局部渗透的风险，并且因此不再可能确保所需的腐蚀控制。
抗腐蚀层在约40HRC下具有比常规热浸镀锌表面更高的硬度。适当时具有钝化的抗腐蚀层可以用作例如使用FNC方法生产的涂层的低成本替代物。在随后的抗磨损层涂覆期间或在车轮制动器的操作期间，抗腐蚀层不应该能够被熔化。因此，熔融冶金应用的涂层不可能作为抗腐蚀层，该涂层总是包含纯锌。
本发明的抗腐蚀层是坚硬的并且可以应用于覆盖整个主体的表面，以使即使在螺钉力的作用下在制动轮毂的区域中也不会有螺钉的松弛和松动。因此，即使在制动盘与轮毂的接触表面上也永久地提供腐蚀控制，并且因此制动盘表面不可能在轴支撑上快速生锈。此外，如果抗腐蚀层也形成在冷却肋上，则本发明的抗腐蚀层能够为通风制动盘的冷却肋提供有效的腐蚀控制。由于这些措施，可以实现约240000km的制动盘寿命，对制动盘的摩擦表面的磨损很小，并且对制动盘的剩余表面没有腐蚀。
抗磨损层可以使用热涂覆方法应用到抗腐蚀层。可以采用的热涂覆方法的示例是高速火焰喷涂的方法。作为最后的操作，可以研磨抗磨损层的暴露表面。抗腐蚀层可以用作活性阴极锌层，而且，该锌层用作随后的HVOF抗磨损层的粗糙键合涂层，这意味着可以不需要抗腐蚀层的进一步的喷射/喷砂处理。
主体可以是环形设计。该主体可以使用砂铸法生产。抗腐蚀层可以在某个区域或某些区域中或完全地应用到轴向摩擦侧。抗磨损层可以在某个区域或某些区域中或完全地应用到抗腐蚀层。主体还可以具有两个轴向摩擦侧，这两个轴向摩擦侧彼此轴向相对地设置并且相应地被涂覆。
制动盘可以配置为未通风制动盘或具有冷却肋的通风制动盘。制动盘在设计上可以是环形或板状的。
陆地车辆可以是机动车辆，特别是汽车或商用车辆。
根据一个有利实施例，使主体的连接到抗腐蚀层的表面***糙。主体的表面可以例如使用高压水射流方法(优选地使用脉动高压水射流)或通过适合的车削操作(更具体地，干燥执行的车削操作)或通过其他形式的机械加工来***糙，以便能够在表面的一部分上产生规定的粗糙度。通过使主体表面***糙，可以进一步实现抗磨损层与主体的粘合牢固性的增加。相比于高压水射流方法，例如，刚玉射击方法会将嵌入的射击粒子留在主体的粗糙表面中。另一方面，高压水射流方法产生主体的清洁表面，在主体表面具有理想的底切和气穴，从而允许例如有效地将HVOF喷射颗粒键入到表面中以形成抗磨损层。以这种方式粗糙和清洁的主体表面理想地适合于随后的用于形成抗腐蚀层的渗锌。在这种情况下，锌被扩散到主体的表面不会受到已经射入的破坏性刚玉颗粒的阻碍。因此，相比于传统的刚玉喷砂，在实施高压水射流方法之后，在主体的表面上没有可能破坏锌扩散到主体的表面中的喷砂残留物。
根据另一个有利的实施例，抗磨损层由含有至少一种氧化物或金属粘合剂的SiC材料制成。SiC材料可以使用热喷涂方法(例如，优选高速火焰喷涂(HVOF)，特别优选具有液体燃料的HVOF)应用到主体的轴向摩擦侧。然而，纯SiC涂层粉末在热涂覆过程中会分解，因此可以用氧化物或金属的壳体包围大小约1μm的碳化硅。例如，该壳体材料吸收来自HVOF火焰的热量并且软化，结果是，当其撞击表面时，其导致具有氧化物或金属的壳体的SiC颗粒的密集涂层。SiC因其非常高的耐磨损性而闻名。此外，SiC具有高导热性，这使其有资格用作制动盘上的抗磨损层。在磨损试验中，已经发现以这种方式涂覆的制动盘不会出现任何盘磨损。由此产生的磨损更令人惊讶，因为硬度测量仅显示平均值刚好超过600HV0.3的中等硬度值。据推测，在硬度测试期间实际上未检测到尺寸仅为1μm的SiC颗粒，并且因此在此测量的是更大的壳体硬度(在这种情况下是氧化物)。SiC本身具有在2200HV0.3以上范围的硬度。
根据另一个有利的实施例，抗磨损层由具有碳化钒增强材料或碳化铌增强材料或碳化硼增强材料或碳化铬增强材料的铁基合金制成。在这种情况下，抗磨损层可以由具有碳化钒的硬铁基合金制成，该碳化钒作为通过与铬合金化而耐腐蚀制造的大体上铁素体基体中的增强组分。喷雾添加剂的钒含量可以大于按重量计6％，优选按重量计17％。这种硬铁基合金不是通过硬基体而是通过极硬的钒碳化物作为增强组分而获得高硬度(在按重量计17％的钒-FeCrV17的情况下约850HV0.3)。由于基体由柔性混合铁晶体构成，因此所涉及的复合材料具有非常高的抗冲击应力和边缘稳定性，并且在许多情况下用于形成切割和刀口。从根本上说，作为硬铁基合金中的合金元素的铌在碳化物的析出行为方面发挥与钒相当的效果。作为含有高比例钒的硬铁基合金的替代物，提出了铌含量高于按重量计8％(优选高于按重量计15％)的那些。具有按重量计至少17％的铬含量和按重量计至少2％的硼含量(优选按重量计25％的铬和按重量计5％的硼)的FeCrBC硬合金获得约900HV0.3的硬度。该系列合金的硬度基于复杂硼化物的形成和极细的微观结构(通常甚至是X射线的无定形)。极其精细的晶体结构也是突出的抗冲击应力的基础。按重量计至少17％(按重量计高达35％)的铬含量会产生高耐腐蚀性。供选择地，包含具有按重量计至少12％(优选按重量计20％至按重量计30％)的铬含量的基于铁的金属基体(以便确保良好的耐腐蚀性)和比例为按重量计至少50％(优选按重量计75％至按重量计80％)的碳化铬(优选Cr3C2)的FeCrC金属-陶瓷复合材料被提出以便获得高层硬度(约900HV0.3至1000HV0.3)和耐磨性。在这种情况下，可以使用通过凝聚(喷雾干燥)和烧结制备的复合粉末，以便一方面，在层中具有特别硬的碳化铬Cr3C2-而不是由熔融相形成的富铬混合碳化物，其在通过涉及熔化的冶金方法生产的常规硬铁基合金中具有脆化效果-并且以便避免通过富集碳来使金属基体脆化，这会降低耐腐蚀性和抗冲击应力。原则上，也可以使用其他硬铁基合金。然而，上述抗磨损材料具有的优点是，从抗腐蚀层磨损的任何材料都不包含任何特别具有高健康危害潜力的元素，例如，镍、钴、铜和钨。所涉及的抗磨损层通过热喷涂方法(优选高速火焰喷涂(HVOF)，特别优选具有液体燃料的HVOF)来生产。
在磨损试验中，已经发现由FeCrV17材料构成的HVOF涂层导致与传统制动衬片配对的优异磨损。因此，与未涂覆的制动盘的测试相比，制动盘上没有磨损并且制动衬片材料的磨损没有增加。例如，水喷射的渗锌主体可以设置有约400μm厚的FeCrV17抗磨损层。形成抗腐蚀层的渗锌涂层遵循主体的粗糙表面，并且因此确保了所需的腐蚀控制。由FeCrV17叶片钢组成的抗磨损层可以包含具有平均尺寸小于2μm的精细分布的钒碳化物，这不仅在制动盘上而且在与之相互作用的传统制动衬片上产生特别低的磨损。
因此，上述抗磨层由低成本材料构成，该低成本材料尽管硬度高但以耐腐蚀性和抗碎石应力为特征。
此外，上述目的通过具有权利要求5的特征的方法来实现，其中抗腐蚀层使用渗锌方法来生产。
针对制动盘上面提到的优点相应地与该方法相关联。特别地，根据上述实施例中的一个或这些实施例中的至少两个的组合的制动盘使用根据本发明的方法来生产。
主体可以使用砂铸法生产。抗磨损层可以使用热涂覆方法(特别是热喷涂方法，优选高速火焰喷涂方法)被应用到抗腐蚀层。
根据有利的实施例，轴向摩擦侧在应用抗腐蚀层之前经受包含车削的机械加工操作。特别地，轴向摩擦侧可以使用包含车削的干式机械加工工艺来机械加工并且因此可以变光滑。
另一个有利的实施例设想，在应用抗腐蚀层之前，使用高压水射流方法或通过机械加工使轴向摩擦侧***糙。上面参照制动盘的相应实施例所述的优点相应地与该实施例关联。
根据另外有利的实施例，抗磨损层使用高速火焰喷涂方法被应用到抗腐蚀层。这使得能够快速生产抗磨损层。
根据另一个有利的实施例，使抗磨损层的背离抗腐蚀层的表面光滑。例如，可以通过磨削使抗磨损层的表面光滑。
尽管上面仅提及了制动盘，但是根据本发明也提供了具有根据本发明的涂层的鼓式制动器。因此，本发明构思还包括用于生产具有根据本发明的涂层(抗腐蚀层/抗磨损层)的鼓式制动器的方法。
附图说明
在从属权利要求和以下附图的描述中公开了本发明的其他有利实施例。在附图中：
图1示出了根据本发明的制动盘的说明性实施例的示意性轴向剖视图；
图2示出了根据本发明的方法的说明性实施例的流程图。
具体实施方式
图1示出了根据本发明的用于陆地车辆(未示出)的车轮制动器(未示出)的制动盘1的说明性实施例的示意性轴向剖视图。
具有环形设计的制动盘1具有环形设计的主体2，该主体2由灰铸铁制成，该主体2具有轴向摩擦侧3、应用到轴向摩擦侧3的环形设计的抗腐蚀层4、应用到抗腐蚀层4的环形设计的抗磨损层5。抗腐蚀层4是渗锌层。连接到抗腐蚀层4的主体2的轴向摩擦侧3的表面被粗糙化。
抗磨损层5可以由包含至少一种氧化物或金属粘合剂的SiC材料制成。供选择地，抗磨损层可以由具有碳化钒增强材料或碳化铌增强材料或碳化硼增强材料或碳化铬增强材料的铁基合金制成。
图2示出了根据本发明的用于生产陆地车辆的车轮制动器的制动盘的方法的一个说明性实施例的流程图。完成的制动盘可以如图1所示进行构造。
在方法步骤10中，生产由灰铸铁构成的主体，该主体具有至少一个轴向摩擦侧。为此目的，可以采用砂铸法。首先轴向摩擦侧经受包含车削的机械加工。之后，使用高压水射流方法使轴向摩擦侧***糙。
在方法步骤20中，抗腐蚀层使用渗锌方法被应用到主体的轴向摩擦侧。
在步骤30中，抗磨损层使用高速火焰喷涂方法被应用到抗腐蚀层。最后，可以使抗磨损层背离抗腐蚀层的表面光滑。
附图标记列表
1 制动盘
2 主体
3 2的摩擦侧
4 抗腐蚀层
5 抗磨损层
10 方法步骤(2的生产)
20 方法步骤(4的应用)
30 方法步骤(5的应用)

Claims (10)

1.一种用于陆地车辆的车轮制动器的制动盘(1)，所述制动盘(1)具有主体(2)，所述主体(2)由灰铸铁制成，所述主体(2)具有至少一个轴向摩擦侧(3)、应用到所述轴向摩擦侧(3)的至少一个抗腐蚀层(4)，和应用到所述抗腐蚀层(4)的至少一个抗磨损层(5)，
其特征在于，
所述抗腐蚀层(4)是渗锌层。
2.根据权利要求1所述的制动盘(1)，
其特征在于，
使所述主体(2)的连接到所述抗腐蚀层(4)的表面***糙。
3.根据权利要求1或2所述的制动盘(1)，
其特征在于，
所述抗磨损层(5)由含有至少一种氧化物或金属粘合剂的SiC材料制成。
4.根据权利要求1或2所述的制动盘(1)，
其特征在于，
所述抗磨损层(5)由具有碳化钒增强材料或碳化铌增强材料或碳化硼增强材料或碳化铬增强材料的铁基合金制成。
5.一种用于生产陆地车辆的车轮制动器的制动盘(1)的方法，其中主体(2)由灰铸铁制成，所述主体具有至少一个轴向摩擦侧(3)，至少一个抗腐蚀层(4)被应用到所述轴向摩擦侧(3)，并且至少一个抗磨损层(5)被应用到所述抗腐蚀层(4)，
其特征在于，
所述抗腐蚀层(4)使用渗锌法来生产。
6.根据权利要求5所述的方法，
其特征在于，
所述轴向摩擦侧(3)在应用所述抗腐蚀层(4)之前经受包含车削的机械加工操作。
7.根据权利要求5或6所述的方法，
其特征在于，
在应用所述抗腐蚀层(4)之前，使用高压水射流方法或通过机械加工使所述轴向摩擦侧(3)***糙。
8.根据权利要求5至7中任一项所述的方法，
其特征在于，
所述抗磨损层(5)使用高速火焰喷涂法被应用到所述抗腐蚀层(4)。
9.根据权利要求5至8中任一项所述的方法，
其特征在于，
使所述抗磨损层(5)的背离所述抗腐蚀层(4)的表面光滑。
10.根据权利要求5至9中任一项所述的方法，
其特征在于，
在抗磨损层的高速火焰喷涂中使用以液体燃料操作的HVOF燃烧器。
CN201910821910.9A 2018-09-04 2019-09-02 制动盘和用于生产制动盘的方法 Pending CN110925338A (zh)

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